Simple relay structure

ABSTRACT

A relay has a coil form part which includes a coil supporting tube and a flange at each end of the tube. The coil form part is formed as a one-piece plastic molding. A stationary core part includes a mounting flange and two, parallel, spaced apart core legs joined to the mounting flange. One of the core legs is inserted through the coil supporting tube of the coil form part. A movable armature structure is fastened to the other core leg, i.e., the leg which is not inserted within the coil supporting tube, in cantilever fashion, at the end of said other core leg remote from the mounting flange. The armature structure includes a movable core part supported thereby in spaced, overlapping relationship to the end of the core leg inserted through the coil supporting tube.

United States Patent [1 1 Hayden et al.

llll 3,893,194

l l July 1,1975

[ SIMPLE RELAY STRUCTURE [75] Inventors: Rodney Hayden, Stoney Creek;Gordon M. Davidson, Grimsley. both of Canada [73] Assignee: TRW Inc.,Cleveland, Ohio [22] Filed: Feb. 27, 1974 [2l] Appl. No.: 446,554

Related U.S. Application Data [63] Continuationin-part of Ser. No.368,398, June 8. 1973, abandoned, which is a continuation of Ser. No.277,843, Aug, 3. I972, abandoned.

[52] US. Cl. 335/202; 335/203; 335/297 [51] Int. Cl. HOlh 45/04 [58]Field of Search 335/202, 203, 187, 297, 335/196, 281, 282

[56] References Cited UNITED STATES PATENTS 3,372,356 3/1968 Hiyane etal 335/297 3,588,765 6/l97l Alten 335/203 3.723.925 3/l973 Alten 335/203Primary Examiner-Harold Broome Attorney, Agent, or Firm-James R,O'Connor [57] ABSTRACT A relay has a coil form part which includes acoil supporting tube and a flange at each end of the tube. The coil formpart is formed as a one-piece plastic molding. A stationary core partincludes a mounting flange and two, parallel, spaced apart core legsjoined to the mounting flange. One of the core legs is inserted throughthe coil supporting tube of the coil form part. A movable armaturestructure is fastened to the other core leg, i.e., the leg which is notinserted within the coil supporting tube, in cantilever fashion, at theend of said other core leg remote from the mounting flange. The armaturestructure includes a movable core part supported thereby in spaced,overlapping relationship to the end of the core leg inserted through thecoil supporting tube.

22 Claims. ll Drawing Figures 1 SIMPLE RELAY STRUCTURE CROSS REFERENCETO RELATED APPLICATION This application is a continuation in part ofcopending application Ser. No. 368,398 filed June 8, 1973, whichapplication was a continuation of now abandoned application Ser. No.277,843 filed Aug. 3, 1972.

BACKGROUND OF THE INVENTION 1. Field of the Invention The inventionrelates to direct current relay constructions of simple, sturdy form andarrangement which are particularly adapted for miniaturization and areparticularly attractive for utilization in automotive applications.

2. Description of the Prior Art Due to the increasing requirement forrelays in automobile electrical circuitry, the demand for sturdy relaystructures adapted to operate reliably for more than one hundredthousand cycles of duty under conditions of vibration, temperaturevariation and humidity has developed an awareness of the structuralweaknesses of conventional relay structures. A conventional relaystructure will ordinarily comprise a coil wound upon a core, a corebeing riveted or bolted to a remainder core part and being fastened toan insulated base. Terminals are fastened to the base by metal rivetsand metal contact structure rising from the base is usually fastened tothe latter by rivets. It has been found that the assembly of relaystructure and parts with an insulated base by metal riveting, pressfitting, clamping or the like is apt to weaken rapidly due to vibrationat a relatively early stage in service. The riveting together of metalcore parts, such as the riveting or bolting of the coil core to theremainder core part likewise tends to loosen. Part of the difficultyarises from the forming of a rigid metal rivet connection between ametal part and a plastic part such as the insulated base. Changingthermal and humidity conditions cause minute changes in the dimensionalcharacteristics of the plastic material about the rivet which in a shorttime develop a loose connection in many automobile relay structures. Anautomobile relay is required to be manufactured in large volume at verylow cost. Thus the number of forming and assembling operations to bepracticed in the manufacture of such relay must be a minimum and must beof simple nature.

It is a main object of the invention to provide a simple relay structureof a direct current type adapted for automotive use embodying a corestructure adapted to conduct both magnetic flux and electrical currentand comprising parallel spaced apart core legs joined at one end by aflange portion with the legs and flange portion being struck from thesame sheet of metal, a movable core part extending between the otherends of the legs and spring means supporting the movable core part todefine a magnetic gap for said core, said core part being adapted forrigid mounting on a supporting base by simple fastening means.

It is another object of the invention to provide a simple relaystructure in which a small number of subassemblies may be connected infinal assembly by fastening means which provide rigid, permanentconnections.

Other objects of the invention will be appreciated by a study of thefollowing specification taken in conjunction with the accompanyingdrawings.

BRIEF DESCRIPTION OF THE DRAWING FIG. 1 is a perspective view of oneembodiment of a simple relay according to the invention;

FIG. 2 is a perspective view of the outer casing for the relay depictedin FIG. 1;

FIG. 3 is a perspective view of the coil form part of the relay;

FIG. 4 is an exploded view of the components of the relay except for theouter casing;

FIG. 5 is an exploded view of the armature components of the relay;

FIG. 6 is a perspective view of another form of a relay core partaccording to another embodiment of the invention;

FIG. 7 is a perspective view of a relay embodying the core part depictedin FIG. 6 and a coil form part especially adapted for miniaturization;

FIG. 8 is a perspective view of the coil form part of the relay depictedin FIG. 7;

FIG. 9 is a perspective view of a removable outer casing adapted forassembly with the base of the coil form part depicted in FIG. 8;

FIG. I0 is a top plan view of the relay structure of FIG. 7; and

FIG. 11 is a bottom plan view of the relay structure of FIG. 7.

DESCRIPTION OF A FIRST EMBODIMENT OF THE INVENTION In the drawings, therelay I0 of the invention generally comprises a coil form part IIembodying an integral base part 12, a hollow spool or winding column 13and upper winding flange 14. The base 12 lockably receives the outercasing 15 containing therewithin the winding 16 on spool 13 and armatureassembly 17 fastened to core part 18 assembled with the coil form part11 in a manner presentingg integrally formed external terminal members19. Thus, on assembly, the base having the winding thereon has insertedtherein the core part 18 to which is assembled the armature assembly 17and including an additional relay contact end terminal assembly 20.These main components provided in the combination and form shown simplfyassembly operations and enable the application of reliable and simpletechniques for fastening the components in assembled position.

In more detail the coil fomi part 11 is formed of a thermoplasticinsulating material in which the base 12 is generally rectangular andgenerally features casing locking recesses 21 adapted to articulate withinwardly extending locking lugs 22 of the outer casing 15. Base 12 andflange l4 embody heat deformable rivet posts 23, 24 and 25 being cast insitu of the same thermoplastic material as the coil form part. Base 12also embodies suitably located slots 26, 27. Coil form column 13embodies a through bore 28 which is preferably rectangular in section.

The outer casing 15 in more detail comprises upstanding walls 29 risingfrom locking flange 30 at the lower outer terminus or open end 31 of thecasing, the other end 32 being closed by a top wall 33. Side walls 34carrying the indented or recessed wall portions 35 are adapted to bepositioned relative to armature assembly 17 within the casing so as totransmit relay noise through contact part 36 located in touchingrelationship with the inner surfaces of a recessed portion 35 of a sidewall 34. The casing is made of a flexurable thermoplastic material sothat the locking flange 30 thereof may have its lugs 22 pressed over thebase I2 for grip ping of lugs 22 in recesses 21 thus to retain thecasing in firm assembly with the base 12.

The stationary core part 18 is struck from a sheet of ferrous materialand includes a mounting flange 37 having two rivet receiving openings38,39 and at right angles to the mounting flange and a laterally foldedwinding core leg 40 spaced from a parallel, spaced apart, upstandingcore leg 41, both of which core legs extend in one direction from themounting flange 37. The two terminal members 19 and 42 extend in theopposite direction at right angle to the mounting flange. The core legs.mounting flange, and terminals are struck from the same sheet of ferrousmaterial to provide a single component for easy assembly of the corelegs 40,41 in the rectangular bore 28 and slot 26 of the coil form partII, respectively, such assembly being accomplished preferably afterwinding 16 has been wound on the exterior of the coil supporting tube 13of the coil form part 11.

As is best seen in FIG. 5, the armature assembly 17 includes anelectrical conductor strip 43 having a movable spring arm portion 44struck therefrom and carrying at its free end 45 a contact bar 46.Movable core part 48, which is also formed from ferrous material. isspot welded to an intermediate portion 47 of the strip 43 at weld points49 in such a manner that the other end 50 of the strip 43 may be spotwelded at points 51 to the rigid upstanding core leg 41 after assemblyof the latter with the coil form part 11. The movable core part 48 is ofsufficient length to overlap surface 52 of the winding core leg 40, butis slightly spaced at its inner end 53 from the nearest edge 54 of thecore leg 41 to provide a flexing portion 55 in the strip 43 of the relayarmature.

The relay contact includes a contact supporting member 36 which has acontact bar 56 disposed thereon at right angles to mounting flange 57having a rivet opening 58 adapated to seat over a rivet post withinantitwist recess 59 of coil form part flange 14 to locate contact bar 56at right angles to and in spaced relation to contact bar 46 of the relayarmature l7. Terminal post 60 is formed of strip metal, as are all theother metal parts of the relay, and embodies a mounting flange 62 havinga rivet receiving opening 63 adapted to seat on rivet post 23 of thecoil form part. The terminal member 60 is adapted to pass through therectangular opening 27 in the coil form part within the antitwist recess64 which is adapted to restrict the terminal flange 62 against twisting.The terminal flange 62 carries a wire connecting post 65. The mountingflange 57 of relay contact 20 likewise carries a wire connecting post66, said posts 65,66 being adapted for connection to the wire ends 67,68 of the coil winding 16. The rivet posts 23,24,25 are deformed by heatto form plastic rivet heads and securely fasten the above describedmetallic relay parts to the coil form part.

As is evident from the foregoing description, the simple relay structureof the described embodiment of the invention provides an insulate coilform part including a base portion, a hollow coil supporting portion anda flange spaced from said base by said coil supporting portion, allformed from an insulating plastic material and having appropriate slotsand associated rivet studs for assembly therewith of the metal relayparts. A magnetizable stationary core part is struck from sheet ferrousmaterial to define spaced apart, rigid core legs, an intermediatesupporting flange and at least one tenninal member extending from saidflange in a direction opposite said core legs, the core legs beinginsertable through a slot in the base and into the core supportingportion of the coil form part. A stationary contact part and terminalpart are mountable, respectively, on the flange and base of the coilform part. The stationary core part, the contact part and the terminalpart each have rivet receiving holes for assembly with the rivet studsof the coil form part and are fastened thereto by heat forming heads onthe rivet studs to provide rigid mechanical connections. The outercasing of the relay includes a side wall portion adapted to physicallyengage the stationary contact part of the relay for the transmission ofsound. The core leg of the stationary core part which is not inserted inthe coil supporting portion of the coil form part supports a movablearmature assembly and movable core part forming a portion of saidarmature assembly.

DESCRIPTION OF A SECOND EMBODIMENT OF THE INVENTION The stationary corepart 18 of FIG. 6 is a modified version of the core part 18 of FIG. 4and represents an optimum form of core structure both for the conductionof magnetic flux and the conduction of direct electric current. Corepart 18 of FIG. 6 is of such a proportionality in its organization ofelements as to be particularly adapted for miniaturization to providevery small relays of high efficiency and high current switchingcapability, but of small physical volume as compared with core parts andrelay structures heretofore used in automotive applications.

Thus, in FIG. 6, the core part 18 is revealed in a form in which theupstanding legs 69 and 70 are each of the same width W, are separated byan opening of width W and extend integrally from a flange 7] of aminimum depth W. A tenninal bar 72 extends from an edge 73 of the flange71 in a plane parallel to, but in a direction opposite to, the legs69,70 and opposite to the similarly dimensioned openings 74 between saidlegs. The core part 18 is struck from a single piece of sheet metal. Thethickness of the metal is preferred, according to this embodiment of theinvention, to be greater than WM and preferably not less than W/3,whereby in stamping opeations the thickness of the ferrous sheet metalstrip to be stamped will, by virtue of the nature of the stampingoperation, tend to determine the value of W for a preferred ratio of W/3 for the thickness of the metal being stamped. Preferably also, theheight of each leg 69,70 is on the order of 3W minimum to permit a coilof a height of at least 2W to be wound thereabout from the flange 71upwards to leave a freestanding portion, for example, freestandingportion 75 on leg 69 having an armature mounting hole 76 to extend abovethe coil or winding region 77. The legs 69,70 are in parallel, spacedapart relationship with respect to planes of their faces, but aretransversely offset by a gap on the order of width G. The most remote(relative to each other) faces of said legs are displaced or offset by adistance equal to the width of the gap G plus the thickness t of thesheet material from which the core part is struck. The leg heights Hpreferably are sufficient to accommodate the height or thickness h ofthe base of the coil form part II shown in a modified form in FIGS. 7and 8 through 11. The value of 11 preferably is on the order of W/2minimum. The overall height of the coil form part 11 of FIG. 8 is on theorder of Y plus it the coil or winding length L which can beaccommodated is on the order of 2W between the flanges 77 and 78 alongthe rectangular, tubular, coil support portion 79 which as a core legreceiving bore 80 extending therethrough and through the base part 81and flange 78. The base part 81 has openings 82, 83, 84 and 85 formedtherethrough, and the upper flange 77 of the modified coil form partincludes an upstanding tab 86 defining a stop which limits the movementof a modified form of armature structure 17 to be described hereinafterwith reference to FIGS. 7 and 10.

Terminal leg 72 communicates electrically with the legs 69,70 by way ofan electrical path through the material of the core part 18 at any pointin said core part of an electrical cross section at least equal to thatof the core terminal leg 72 and, for this reason, the thickness of theflange 71 which serves as an electrical connection between legs 69,70and terminal leg 72 must be sufficient to afford this desired crosssection of electrical pathway. Furthermore, the magnetic pathway betweenthe legs 69 and 70 through the flange 71 of the core part must notencounter any diminution of cross section for conducting magnetic flux.As is best depicted in FIG. 7, the core part 18 of FIG. 6 is insertedinto the coil supporting tube of the modified coil form part 11 of FIG.8 by inserting core leg 70 into the bore 80 from beneath the coil formpart base 81 while simultaneously inserting core leg 69 through baseopening 83 until the barbed protuberance 87 on leg 70 (see FIG. 6),which is in scraping engagement with the inner surface 88 of the coilsupport tube 79 defining bore 80, arrives at its final position in thebore as determined by full seating of the core part base 71 in therecess 89 of coil form part base 81 (see FIG. 11). Prior to the assemblyof the core part 18 of FIG. 6 with the coil form part 11 of FIG. 8, asuitable relay winding 90 is wound on the coil support tube 79 of thecoil form part 11. The core part 18 is then assembled with the coil formpart 11 as described above. The terminal leg 91 extends through coilform part base opening 84 and rises thereabove and includes a lockingflange 92 extending inwardly, i.e., toward the coil 90, and anupstanding stationary contct arm 93 joined to the flange 92 and suitablyspaced laterally by a gap 94 from the core leg 70 as indicated in FIG.10. The armature member 95 is preferably formed from a springy bronzematerial and is fastened by a rivet 96 to the free end 75 of core leg 69and, optionally, an overlying current conducting brass strip 97 isriveted, soldered. or welded to the armature member 95 and is riveted,soldered or welded to an adjacent face 98 of the leg 69 as at 99 (seeFIG. 7) to provide increased electrical conduction from leg 69 toarmature 95. The movable core part 100 is riveted or otherwise fastenedto the inner face 101 of armature 95 and is of the length 2W andoverlies the adjacent surface 102 of the upper end of core leg 70. Themovable core part 100 is spaced from the surface 102 by a distanceapproximately equal to the width of gap G, and the free end 103 of thearmature carries a movable contact 104 adapted to articulate with afixed contact 105 carried by the stationary contact arm 93.

Terminal members 106 and 107 are similar and rise from the coil formpart base 81 for the connection thereto of the wires of the coil 90,whereas terminals 72 and 91 as seen in FIG. 11 provide electricalconnections to the movable contact 104 and stationary contact 105,respectively. In the form shown the relay structure is in the normallyopen condition at which stop member 86 limits the outward position ofthe springy bronze armature thus determining a satisfactory tolerancefor the contact gap 108.

It has been found that the core structure of FIG. 6, which is both anelectrical and magnetic flux conducting core structure, is of aproportionate efficiency with respect to both electrical and magneticfunctions and striking the same from a thinner magnetic flux conductingmetal strip and appropriately adjusting the value of W as suggestedherein leads to a surprisingly small physical size of relay for thehandling of relatively large currents in automotive circuitry. Thus, thedimensions of housing 109 as shown in FIG. 9, which encloses thestructure of FIG. 7 are ideally on the order of a maximum heightdimension D; of approximately one centimeter for a current switchingcapability on the order of 20 amperes at a 50% duty cycle. Thedimensions D and D are each less than the value of D,,. Primarily, thelast described core part 18 will be recognized as a direct current typeof C core wherein the flange portion 71 extending between the legs 69,70is struck from the same sheet of metal stock as said legs. In the lastdescribed embodiment, the legs and flange are all preferably of the samewidth and thickness as compared with the folded form of leg 40 of theFIG. 5 embodiment, although the latter provides the same flux conductingsection as the wider leg 41. Thus, the invention pro vides for asimplicity of organization of relay components with attendant electriccurrent and magnetic flux conducting efficiency, enabling substantiallyproportional miniaturization according to size requirements whilemaintaining substantially optimum flux and electric current conductingefiiciency.

The core parts shown in FIGS. 4 and 6 may, if desired, be fastened tothe bases of coil form parts 11 by the use of adhesive coated surfaces110, 111 and 112, as shown in FIG. 6. By way of example, an adhesivehaving high heat resistance and electrical insulating properties such asan elastomer resin neoprene based adhesive in solvent may be applied asat 100, 111 and 112, as well as to the undersurface region as at 113 ofthe base 81 of coil form part 11. If adhesive fastening were employedwith the earlier described first embodiment, then the heat deformationof the rivet studs 23, 24 and 25 of FIGS. 3 and 4 may be renderedunnecessary, the rivets then serving only as convenient locating devicesfor the metal parts to be fastened. Furthermore, the inventioncontemplates the use of an adhesive in the fastening of each of theterminals 91, 107 and 108 through the base of the coil form part 11,while peripheral surfaces 114 of the base, as seen in FIG. 8, maylikewise be coated with adhesive to effect a more permanent fastening ofthe casing 109 to the coil form part. The invention thus provides asimple relay structure adapted to be entirely hermetically sealed fromthe atmosphere in that neoprene based adhesives afford excellentadhesion and bond and enjoy an extended life even when under attack byacids, oils, gasoline and other substances which may tend to promotecorrosion.

We claim:

1. A relay structure comprising: a coil form part, said coil form partincluding a coil supporting tube and a flange at each end of said tube,said tube and said flanges being formed as one piece of an insulatingmaterial', a stationary core part, said core part including a mountingflange and two, parallel, spaced apart core legs joined to and extendingfrom said mounting flange, one of said core legs being inserted withinsaid coil supporting tube; and a movable armature structure fastened incantilever manner to the other of said core legs proximate the endthereof remote from said mounting flange, said armature structureincluding a movable core part supported thereby in overlapping, spacedrelationship to the end of said one core leg remote from said mountingflange.

2. A relay structure comprising: a coil form part, said coil form partincluding a coil supporting tube, a flange joined to one end of saidtube and a base joined to the other end of said tube, said tube. flangeand base being formed of an insulating material; a core part mounted onsaid base, said core part including a mounting flange having at leastone rivet receiving hole therein, a terminal part joined to saidmounting flange and extending at right angles from said mounting flange,and two parallel, spaced apart core legs joined to and extending fromsaid mounting flange in a direction opposite said terminal part, one ofsaid core legs being inserted within said coil supporting tube; at leastone other terminal member having a mounting flange and a rivet receivinghole in said flange; rivets disposed in the holes of said mountingflanges rigidly fastening each of said mounting flanges to said coilform part; and a movable armature structure fastened to the other ofsaid core legs.

3. A relay structure according to claim 2 wherein said core partcomprises a ferrous sheet metal stamping and said one of said core legsincludes a folded thickness of said ferrous sheet.

4. A relay structure according to claim 2 wherein said coil form partincludes a mounting flange receiving recess for restraining twist of amounting flange riveted thereto.

5. A relay structure according to claim 2 wherein said coil form partincludes a mounting flange receiving recess for restraining a flangemounted therein against twist and a slot associated with said recess forreceiving and rigidly retaining a portion of a part associated with saidmounting flange.

6. A relay structure according to claim 2 wherein said tube. flange andbase of said coil form part are formed as one piece of a heat deformableinsulating material.

7. A relay structure according to claim 6 wherein said rivets are formedintegral with said coil form part.

8. A relay structure according to claim 2 wherein said base of said coilform part has a slot formed therein and said other of said core legsextends through said slot.

9. A relay structure according to claim 8 wherein said mounting flangeof said core part is fixed against the surface of said coil form partremote from said coil supporting tube.

10. A relay structure comprising: a coil form part in the form of a coilsupporting tube having a flange at one end and a base at the other endformed in one piece of a heat deformable insulating material, a corepart in the form of a mounting flange joining at least one terminal partextending at right angles therefrom to parallel spaced apart core legsextending therefrom in an opposite direction, said mounting flangehaving at least one rivet hole therein, at least one other terminalmember having a mounting flange and a rivet hole therein, a slot in saidbase positioned to accommodate one of said core legs through said base,the other of said legs being inserted within said coil supporting tube,a rivet for the hole of each of said mounting flanges, each rivetextending from and being formed of the material of said coil form partand rigidly fastening each said mounting flange to the coil form part,and a movable armature structure fastened to said one of said core legs.

11. A relay structure according to claim 10 wherein said core partcomprises a ferrous sheet metal stamping and the other of said core legscomprises a folded thickness of said ferrous sheet.

12. A relay structure according to claim 10 including a mounting flangeaccommodating recess in said coil form part for restraining twist of amounting flange riveted thereto.

13. A relay structure according to claim 10 including a mounting flangeaccommodating recess in said coil form part for restraining a flangemounted therein against twist and a slot associated with said recess forrigidly accommodating a portion of a part associated with said mountingflange.

14. A relay comprising: a stationary core structure in the form of aferrous sheet metal stamping for conducting both magnetic flux andelectric current, said core structure including two, parallel, spacedapart core legs of substantially equal cross sectional area separated byan opening of substantially the same width as said core legs, said corelegs being connected at one end thereof by an integral flange extendingtherebetween, a movable core part physically connected to the other endof one of said legs and overlying the other end of the other of saidlegs, and spring means supporting said movable core part to provide amagnetic gap between said movable core part and said other leg.

15. A relay according to claim 14 wherein said stationary core legs areof substantially equal length and width.

16. A relay according to claim 14 wherein one of said core legs isfolded longitudinally.

17. A relay according to claim 14 wherein said movable core partoverlies an area of the other of said core legs equal to the square ofthe width of said other leg.

18. A relay according to claim 14 including an insulate base and meansrigidly fastening said flange of said core structure to said insulatebase.

19. A relay according to claim 14 including an insulate base and aplurality of terminal members, said flange and said terminal membersbeing adhesively fastened to said base.

20. A relay according to claim 14 including an insulate base, aplurality of terminal members and insulate means fastening said flangeof said core structure and said terminal members to said base, a relaycasing rising from said base, and means adhesively joining said casingto said base to hermetically seal said core structure within saidcasing.

21. A relay according to claim 14 including an insulate base having acoil support rising therefrom, said coil support having a through axialbore, a slot in said insulate base in predetennined location relative tosaid coil support bore, said one of said legs being seated in said slot,said other leg of said core structure being seated in said bore in saidcoil support, and means disposed between opposed surfaces of saidinsulate base, said coil support and said stationary core structure fas-10 having a width W and a length 4W rigidly connected at one end to theend of said first leg remote from said flange and extending therefromacross said opening and beyond the end of said second leg remote fromsaid flange, and a movable core part having a thickness 2, a nominalwidth W and a nominal length 2W fixed to said armature proximate saidfirst core leg and overlying the end of said second core leg remote fromsaid flange in spaced relationship thereto.

1. A relay structure comprising: a coil form part, said coil form partincluding a coil supporting tube and a flange at each end of said tube,said tube and said flanges being formed as one piece of an insulatingmaterial; a stationary core part, said core part including a mountingflange and two, parallel, spaced apart core legs joined to and extendingfrom said mounting flange, one of said core legs being inserted withinsaid coil supporting tube; and a movable armature structure fastened incantilever manner to the other of said core legs proximate the endthereof remote from said mounting flange, said armature structureincluding a movable core part supported thereby in overlapping, spacedrelationship to the end of said one core leg remote from said mountingflange.
 2. A relay structure comprising: a coil form part, said coilform part including a coil supporting tube, a flange joined to one endof said tube and a base joined to the other end of said tube, said tube,flange and base being formed of an insulating material; a core partmounted on said base, said core part including a mounting flange havingat least one rivet receiving hole therein, a terminal part joined tosaid mounting flange and extending at right angles from said mountingflange, and two parallel, spaced apart core legs joined to and extendingfrom said mounting flange in a direction opposite said terminal part,one of said core legs being inserted within said coil supporting tube;at least one other terminal member having a mounting flange and a rivetreceiving hole in said flange; rivets disposed in the holes of saidmounting flanges rigidly fastening each of said mounting flanges to saidcoil form part; and a movable armature structure fastened to the otherof said core legs.
 3. A relay structure according to claim 2 whereinsaid core part comprises a ferrous sheet metal stamping and said one ofsaid core legs includes a folded thickness of said ferrous sheet.
 4. Arelay structure according to claim 2 wherein said coil form partincludes a mounting flange receiving recess for restraining twist of amounting flange riveted thereto.
 5. A relay structure according to claim2 wherein said coil form part includes a mounting flange receivingrecess for restraining a flange mounted therein against twist and a slotassociated with said recess for receiving and rigidly retaining aportion of a part associated with said mounting flange.
 6. A relaystructure according to claim 2 wherein said tube, flange and base ofsaid coil form part are formed as one piece of a heat deformableinsulating material.
 7. A relay structure according to claim 6 whereinsaid rivets are formed integral with said coil form part.
 8. A relaystructure according to claim 2 wherein said base of said coil form parthas a slot formed therein and said other of said core legs extendsthrough said slot.
 9. A relay structure according to claim 8 whereinsaid mounting flange of said core part is fixed against the surface ofsaid coil form part remote from said coil supporting tube.
 10. A relaystructure comprising: a coil form part in the form of a coil supportingtube having a flange at one end and a base at the other end formed inone piece of a heat deformable insulating material, a core part in theform of a mounting flange joining at least one terminal part extendingat right angles therefrom to parallel spaced apart core legs extendingtherefrom in an opposite direction, said mounting flange having at leastone rivet hole therein, at least one other terminal member having amounting flange and a rivet hole therein, a slot in said base positionedto accommodate one of said core legs through said base, the other ofsaid legs being inserted within said coil supporting tube, a rivet forthe hole of each of said mounting flanges, each rivet extending from andbeing formed of the material of said coil form part and rigidlyfastening each said mounting flange to the coil form part, and a movablearmature structure fastened to said one of said core legs.
 11. A relaystructure according to claim 10 wherein said core part comprises aferrous sheet metal stamping and the other of said core legs comprises afolded thickness of said ferrous sheet.
 12. A relay structure accordingto claim 10 including a mounting flange accommodating recess in saidcoil form part for restraining twist of a mounting flange rivetedthereto.
 13. A relay structure according to claim 10 including amounting flange accommodating recess in said coil form part forrestraining a flange mounted therein against twist and a slot associatedwith said recess for rigidly accommodating a portion of a partassociated with said mounting flange.
 14. A relay comprising: astationary core structure in the form of a ferrous sheet metal stampingfor conducting both magnetic flux and electric current, said corestructure including two, parallel, spaced apart core legs ofsubstantially equal cross sectional area separated by an opening ofsubstantially the same width as said core legs, said core legs beingconnected at one end thereof by an integral flange extendingtherebetween, a movable core part physically connected to the other endof one of said legs and overlying the other end of the other of saidlegs, and spring means supporting said movable core part to provide amagnetic gap between said movable core part and said other leg.
 15. Arelay according to claim 14 wherein said stationary core legs are ofsubstantially equal length and width.
 16. A relay according to claim 14wherein one of said core legs is folded longitudinally.
 17. A relayaccording to claim 14 wherein said movable core part overlies an area ofthe other of said core legs equal to the square of the width of saidother leg.
 18. A relay according to claim 14 including an insulate baseand means rigidly fastening said flange of said core structure to saidinsulate base.
 19. A relay according to claim 14 including an insulatebase and a plurality of terminal members, said flange and said terminalmembers being adhesively fastened to said base.
 20. A relay according toclaim 14 including an insulate base, a plurality of terminal members andinsulate means fastening said flange of said core structure and saidterminal members to said base, a relay casing rising from said base, andmeans adhesively joining said casing to said base to hermetically sealsaid core structure within said casing.
 21. A relay according to claim14 including an insulate base having a coil support rising therefrom,said coil support having a through axial bore, a slot in said insulatebase in predetermined location relative to said coil support bore, saidone of said legs being seated in said slot, said other leg of said corestructure being seated in said bore in said coil support, and meansdisposed between opposed surfaces of said insulate base, said coilsupport and said stationary core structure fastening said core structureto said base and said coil support.
 22. A relay comprising a stationarycore part formed from a ferrous sheet metal stamping of uniformthickness t, said core part including first and second parallel, spacedapart core legs and a core flange connected said legs, said legs beingseparated by an opening having a width W and extending integrally fromsaid flange, each of said legs having a width W, a length greater than3W and a thickness greater than W/4, a flexible armature member formedfrom springy sheet metal having a width W and a length 4W rigidlyconnected at one end to the end of said first leg remote from saidflange and extending therefrom across said opening and beyond the end ofsaid second leg remote from said flange, and a movable core part havinga thickness t, a nominal width W and a nominal length 2W fixed to saidarmature proximate said first core leg and overlying the end of saidsecond core leg remote from said flange in spaced relationship thereto.